For the 10 years my unit was under warranty I simply called the people who installed it, they'd come out, cut off the burned wire ends add some inadequate crimped on connectors and it would work for 6-12 more months. Now that the warranty has run out this has become my job. This summer it's begun doing this more frequently and the events seem to be getting closer and closer together. I'm pretty sure this even happen upon startup because I've heard the breakers snap a couple of times shortly after the indoor fan comes on, and when I go out and look the leads are burned.
Based on advice I got here I installed a set of Term-Loc leads about 6 weeks ago. A week ago these leads burned (just like the old ones). The connectors stayed on but one lead burned completely off its Term-Loc connector. The event melted/burned up the plastic terminal separator that comes in the Term-Loc kit. I wasn't able to attach the burned off lead to the Term-Loc connector again, so I went back to my old method that used to last 6 months to a year. Night before last the same lead burned off again.
My question is, what causes compressor leads to burn off of terminals repeatedly like this? Remember it has been happening fairly regularly for 12 years so it isn't a condition caused by age.
This unit has a black cylindrical thing connected to the run capacitor. It has the name Supco Super-Boost. [See picture